US 11,865,642 B2
Additive manufactured ferrous components
Brian Drier, Indianapolis, IN (US); Amanda Dawn Graham, Shelbyville, IN (US); Robert Frederick Proctor, Carmel, IN (US); Quinlan Yee Shuck, Indianapolis, IN (US); and Jacque Sue Bader, Martinsville, IN (US)
Assigned to Rolls-Royce Corporation, Indianapolis, IN (US)
Filed by Rolls-Royce Corporation, Indianapolis, IN (US)
Filed on Sep. 9, 2020, as Appl. No. 17/016,040.
Claims priority of provisional application 62/900,008, filed on Sep. 13, 2019.
Prior Publication US 2021/0078108 A1, Mar. 18, 2021
Int. Cl. B23K 26/342 (2014.01); B33Y 10/00 (2015.01); B33Y 30/00 (2015.01); B23K 26/144 (2014.01); B33Y 70/10 (2020.01); B23K 26/00 (2014.01); B23K 26/08 (2014.01); B23K 26/14 (2014.01); C22C 38/44 (2006.01); C22C 38/46 (2006.01); C22C 38/52 (2006.01); B23K 103/00 (2006.01); B23K 103/02 (2006.01)
CPC B23K 26/342 (2015.10) [B23K 26/0006 (2013.01); B23K 26/08 (2013.01); B23K 26/144 (2015.10); B23K 26/1464 (2013.01); B33Y 10/00 (2014.12); B33Y 30/00 (2014.12); B33Y 70/10 (2020.01); C22C 38/44 (2013.01); C22C 38/46 (2013.01); C22C 38/52 (2013.01); B23K 2103/02 (2018.08); B23K 2103/50 (2018.08)] 17 Claims
OG exemplary drawing
 
1. A method comprising:
removing a damaged portion of a substrate to form an exposed surface of the substrate, wherein the damaged portion removed from the substrate includes a case hardened material,
delivering, by a material delivery device, a filler material to the exposed surface of a substrate, wherein the substrate comprises a first ferrous material, wherein the filler material comprises a second ferrous material and a carbon-based material;
directing, by an energy delivery device, an energy toward a volume of the filler material to join at least some of the filler material to the exposed substrate to form a component, wherein the joined filler material replaces the case hardened material of the damaged portion of the substrate; and
heat treating the at least some filler material joined to the substrate to case-harden a layer, wherein heat treating the at least some filler material joined to the substrate to case-harden the layer includes directed laser hardening of the at least some filler material joined to the substrate with the energy delivery device to case-harden the layer.